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FH1005.142.F1B-00
Contents
1. Technical Specifications
2. Brief Introduction of Construction
3. Maintenance and Repair
4. Disassembly and Re-assembly of Major Components
ZPMC 1
Instructions of the Reducer FH1005.142.F1B-00
Preface
To operate and maintain the reducer correctly the customer shall read these
instructions carefully before operation.
This is a kind of horizontally mounted cylindrical helical gear reducer with parallel shafts
and 4 stages of reduction. This type of reducer is suitable for trolley device or other
mechanism which has the same requirements. The gear strength and material quality
are fully in compliance with requirements of American standard ANSI/AGMA2101-D04.
The reducer is standard product of ZPMC and by many times improvement. Lubrication
is of bath and splash type. All the bearings are spherical (self-aligning) roller bearings
that are sufficiently safe and reliable. This type of reducer has been operated together
with ZPMC’ container cranes in many important ports in the world. Comments from the
customers are appreciated for continuous improvement of the product.
• In these instruction all the data are measured in the international unit system SI unit
(metric system).
ZPMC 2
Instructions of the Reducer FH1005.142.F1B-00
1. Technical Specification
and electromotor)
The reducer is horizontally mounted with parallel shafts and four stages of reduction
and cylindrical helical gears. The reducer has 2 versions of layout (version G/H , see
construction drawing).
The housing is of split type and consists of upper and lower housing. There is
lubrication bath at bottom of the casing, the 1nd pinion are placed under the section, all
of this shaft parts are immersed in the oil and when the gears running the oil will be
splashed to every meshed gear tooth surface and the race way of bearing for
lubrication and heat dissipation.
There is two view covers on the top of the upper housing, when it is opened the gear
meshing condition and backlash may be inspected through the hatch. The housing is
fitted with an air filter C-M42x2 to keep the atmosphere pressure in the housing.
On the left side of the lower housing an oil drainage valve Q11F-16T (DN25) is fitted,
and can be opened for oil replacement or housing cleaning.
ZPMC 3
Instructions of the Reducer FH1005.142.F1B-00
An oil level indicator YWZ-76 is fitted on the left side of the housing (see the side view
on the construction drawing). The oil level of reducer shall be kept at its middle scale.
To prevent oil from going out, every through cover of the shaft is provided double-oil
seals and full of lubricant grease in between the two seals. Outside of bearing cover,
there is a grease nozzle, pour into grease time in order to reliability seal per 3 months.
Sealant are used in the surfaces of the link housing and the blank cover of bearing, it
can prevent oil leakage availability.
ZPMC 4
Instructions of the Reducer FH1005.142.F1B-00
oil, the housing must be flushed with oil to remove sludge, metallic particles and
oil residue. It shall be avoided flushing the gear units with the soluble liquid.
3.6.4 Ensure that all residues have been removed before filling with fresh oil.
3.6.5 Drain the oil while it is still warm, i.e. immediately after switching the machinery
off.
3.6.6 Stop the gear unit by switching off the drive assembly.
3.7 Bearings and oil seals’ lubrication: commend using the lithium-base grease, period
adding ration lubrication according to the requirement of the grease nipple ‘s plate.
3.8 Periodically check the installation bolts for loosening.
3.9 Regularly check the coaxiality of input and output shafts to avoid the reducer from
vibration, heating and abnormal wearing that affect the service life.
3.10 Storage: ZPMC reducer passed trial run check, anti-rust for inner parts, coating
anti-rust oil and lubricate grease on shaft surface, then refer it to the customer. For
long-term storage reducer, laying down effective safeguard is duty of reducer owner.
We advice the storage place is dryness, the temperature is controlled. It isn’t allow
storage at the place where appear dew point, in order to avoid of vapor condense on
the surface of gear, pinion and bearing. Check the inner parts of reducer every month. If
the moisture is found, removed at once, recoat anti-rust oil to protect.
3.11 For the reducer of long-distance transport, prevent due to a difference
temperature change, the parts surface form dew lead to rust. before sent out goods,
add in lubricating oil and rust inhibitor. When the reducer is used, only check up
water in the housing, if there is no, and not have to change lubricate oil.
3.12 Correct operation, maintenance comply with these instructions may ensure
long service life of the reducer, and the reducer life is same as crane. However, the
customer shall establish maintenance and overhaul plan in accordance with the
actual operation condition. The aim is providing the reducer on adjustment after a
certain long operation for longer service life. Normally, overhaul interval shall be 3-5
years depending on actual operation of the crane by the customer.
3.13 Major items of inspection during overhauling:
(1) Any pitting, peeling off, scratch, serious wear etc. on gear teeth surfaces.
(2) Check bearing rollers, internal and external raceway surface, any damage of
retainers.
(3) Check the oil seals.
(4) Clean all the parts, housing and oil passages.
3.14 Inspection, parts and oil replacement shall be carefully recorded.
ZPMC 5
Instructions of the Reducer FH1005.142.F1B-00
ZPMC 6
Instructions of the Reducer FH1005.142.F1B-00
Contact spots on gear teeth surface shall not be less than 35% along the tooth
height and not less than 60% along tooth length. The spots distribution shall be around
the middle zone of the tooth face.
(7) After the above adjustment and installation have been completed place the upper
housing in position, Firstly set the tapered pin into the pin hole, then fit the securing
bolts, nuts. The faying surfaces may be coated with sealing coating.
(8) When the bearings, gears, oil seals and the parts which have relative movement
are fitted up a little clean oil shall be poured onto them to avoid dry friction during
first run.
(9) If oil seals are aged, fractured or seriously worn out they shall be replaced timely.
(10) The securing bolts (8.8 grade), screws (8 grade) shall be tightened with specified
torque as shown in the following table.
(12) The customer shall damage no any part or component during the reducer
disassembly.
(13) After re-assembly the reducer shall be run without load in both directions for at
least 0.5 hour.
(14) During trial run check every joint surface and sealing and there shall not be any
leakage.
(15) During trial run noise level shall not be higher than 85dB and no vibration by
hand feeling.
(16) Turn the input shaft by hand; it shall be manoeuvrable without any jam.
(17) If need be buy vulnerability spare parts that according to the recommendation of
the appendix.
ZPMC 7
Instructions of the Reducer FH1005.142.F1B-00
Note: The above table just lists the type of SKF bearing. Other brands can be selected
according to the relevant SKF type.
ZPMC 8
Instructions of the Reducer FH1005.142.F1B-00
2 SB AB 3409 G1 65*90*13 1
3 SC AC 5558 E1 280*316*18 2
ZPMC 9
Instructions of the Reducer FH1005.142.F1B-00
ZPMC 10
Instructions of the Reducer FH1005.142.F1B-00
Note:
1) Mineral oils in accordance with designation GB5903-95. They are suitable for
operating temperature approx -100C ~ +900C. (short time +1000C)
2) Low Pour Point Mineral Oils is just used in ZPMC’s gear box for the first time
fill-in. They are suitable for operating temperature approx -200C ~ +900C. (short
time +1000C)
3) The synthetic oils have a wider temperature range and a higher viscosity index than
the mineral oils. They are suitable for operating temperature approx -350C ~
+1000C.
ZPMC 11